Hybrid material

ABSTRACT

A process of making a family cell of homogenous inner bladders with varying elasticity includes a forming a plurality of inner bladders from a first material with a first elasticity. The inner bladders have interior surfaces during inner chambers and exterior surfaces exposed to an outside environment. The inner chambers are configured to store a fluid. A family cell is formed by fluidly connecting the inner bladders. One or more hybrid bladders are selected from the inner bladders and a second material having a second elasticity is applied to the hybrid bladders. The second elasticity is less than the first elasticity, such that the second material reduces the elastic qualities of the hybrid bladder.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to U.S. Provisional Patent ApplicationNo. 62/252,141 filed on Nov. 6, 2015, which is incorporated herein byreference.

FIELD OF THE INVENTION

The subject disclosure relates to a manufacturing method and product forcontrolled reduction of elastomeric capability to change elongationcharacteristics in material.

BACKGROUND OF THE INVENTION

Many patented technologies, although novel and non-obvious, can also bedetermined to be cost prohibitive and non-manufacturable. This is thecase for some hybrid materials such as materials that require thecombination of multiple materials to create materials for achievingresults such as the need to create different elastomeric capabilitymaterials for the manufacture of products relating to cell flowtechnology.

Cell flow technology as described in U.S. Pat. No. 8,720,473 issued toAlemida et al. and U.S. Patent Publication US 2015-0208761 A1, publishedon Jul. 30, 2015, each of which is incorporated herein by reference.Cell flow technology is reliant on both the ability to hold gas orliquid as well as control the elongation and flow between each of theindividual bladders. There is a need to be able to manufacture hybridmaterials in a cost effective way using a superior method.

One way to achieve different capability between sealed bladders is toseparate the bladders with the use of valves and channels. This createsseparate sealed bladders that can use different materials to achievevaried densities or elastomeric capability. This method is both costlyand often creates an unsightly final product.

Another way to achieve multiple bladders with different capability is tocreate hybrid material by edge or seam bonding the material togetherprior to welding the material into a bladder. This is both costly andproblematic. Similarly, using multiple layers and variable quantities oflayers while bonding to a bladder is problematic because it is harder toachieve a tight seal and create a leak-proof bladder. This method isparticularly difficult to implement when the product will be used in acushion, as the resultant product can have a surface which isuncomfortable for a user.

SUMMARY

In one embodiment, the subject disclosure relates to a product, process,or method for manufacturing a hybrid material having dual qualities thatis practical and cost effective. Further, the subject disclosure relatesto a product, or method or process of making a product that isleak-proof and comfortable for a user.

In one embodiment, the subject technology is directed to a process ofmaking a family cell of homogenous inner bladders with varyingelasticity. The process includes forming a plurality of inner bladdersfrom a first material, the first material having a first elasticity.Each of the plurality of inner bladders has an interior surface definingan inner chamber, the inner chamber configured to store a fluid therein.An exterior surface of the inner bladders is exposed to an outsideenvironment.

A family cell is formed by fluidly connecting the plurality of innerbladders. At least one hybrid bladder is selected from the plurality ofinner bladders. On the exterior surface of at least one hybrid bladder,a second material having a second elasticity is placed. The secondelasticity is less than the first elasticity and the second materialreduces the elastic qualities of one or more of hybrid bladders.

The second material can be one of the following: molded; laminated;cast; or silk screened. In at least one embodiment, second materialincreases heat dissipation across one or more of the hybrid bladders.The second material can also increase air circulation across the atleast one hybrid bladders. In at least one embodiment, family cell canbe connected to a sports helmet to reduce the likelihood of headinjuries.

The hybrid material can be arranged in a variable pattern. The variablepattern can dampen vibrations across one or more of the hybrid bladders.The variable pattern can also create at least one zone of varyingelasticity across the family cell. At least one variable pattern cancorrespond with a pressure mapping diagram, the pressure mapping diagramreflecting areas of expected pressure between a cushion and a user.

The second material can have a hardness of 65 to 85 Shore A. The secondmaterial can be formed by copper or diamond paste. The second materialcan be formed from polymer urethane and can shield one or more hybridbladders from electromagnetic and radio waves. The second material canbe silicone and can dissipate heat across one or more hybrid bladders.

In one embodiment, the subject technology is directed towards a cushion.The cushion has an inner bladder having a first material of a firstelasticity. The cushion also has a second material having a secondelasticity. The second material is connected to an exterior surface ofthe inner bladder and forms a part thereon. The second material reducesthe elasticity of the inner bladder. The cushion may be employed withthe innersole of a shoe.

In another embodiment, the subject technology relates to a method ofcontrolling elongation of connected fabrics. The method includesconnecting at least two first fabrics, the first fabric formed by afirst material having a first elasticity. The method also includesattaching a second fabric, the second fabric formed by a second materialhaving a second elasticity to the first fabric. The second elasticity issubstantially less than the first elasticity. The second material canform at least one variable pattern. In some embodiments, at least onevariable pattern corresponds with a pressure mapping diagram, thepressure mapping diagram reflecting areas of expected pressure between acushion and a user.

It should be appreciated that the subject technology can be implementedand utilized in numerous ways, including without limitation as aprocess, an apparatus, a system, a device, and a method for applicationsnow known and later developed. These and other unique features of thesystem disclosed herein will become more readily apparent from thefollowing description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those having ordinary skill in the art to which the disclosedsystem appertains will more readily understand how to make and use thesame, reference may be had to the attached drawings that illustrate theeffect on just a flat stretch material and a welded bladder drawingillustrating the effect of the dampening on the welded bladder.

FIG. 1 is an overhead view of a family cell employed with a shoe sole.

FIG. 2 is a side view of the shoe sole of FIG. 1.

FIG. 3 is an overhead view of the shoe sole of FIG. 1 having a differentbladder and conduit configuration.

FIG. 4 is an overhead view of the shoe sole of FIG. 1 having a differentbladder and conduit configuration.

FIG. 5 is an overhead view of a family cell in accordance with thesubject technology, employed with a shoe sole.

FIG. 6 is a side view of the shoe sole of FIG. 5 showing the varyingheights of the stretched inner bladders.

FIG. 7 is an overhead view of a family cell in accordance with thesubject technology, in both an inflated and deflated state.

FIG. 8 is an overhead view of a family cell employed with a shoe solethat is lacks the second material of the subject technology.

FIG. 9 is an overhead view of the family cell of FIG. 8 in both aninflated and deflated state.

FIG. 10 is an overhead view of a family cell in accordance with thesubject technology, employed with a shoe sole.

FIG. 11 is a side view of the family cell of FIG. 10 showing the varyingheights of the stretched inner bladders.

FIG. 12 is an overhead view of a family cell employed with a shoe solethat is lacks the second material of the subject technology.

FIG. 13 is a side view of the family cell of FIG. 12 showing height ofthe stretched inner bladders.

FIG. 14 is an overhead view of a family cell having a variable patternof second material in accordance with the subject technology employedwith a shoe sole.

FIG. 15 is a perspective view of the family cell of FIG. 14 in adeflated state.

FIG. 16 is a perspective view of the family cell of FIG. 14 in aninflated state.

FIG. 17 is a side view of the family cell of FIG. 15

FIG. 18 is a side view of the family cell of FIG. 16.

FIG. 19 is an overhead view of a family cell having a variable patternof second material in accordance with the subject technology employedwith a shoe sole.

FIG. 20 is an overhead view of a family cell having a variable patternof second material in accordance with the subject technology employedwith a shoe sole.

FIG. 21 is an overhead view of a family cell having a variable patternof second material in accordance with the subject technology employedwith a shoe sole.

FIG. 22 is an overhead view of a family cell having a variable patternof second material in accordance with the subject technology employedwith a shoe sole.

FIG. 23 is an overhead view of a family cell in accordance with thesubject technology employed with a fabric forming a pillow.

FIG. 24 is a perspective view of the pillow of FIG. 23 in an inflatedstate.

FIG. 25 is an overhead view of a family cell in accordance with thesubject technology employed with a fabric.

FIG. 26 is an overhead view of a family cell in accordance with thesubject technology employed with a fabric

FIG. 27 is a perspective view of a family cell in accordance with thesubject technology employed in a fabric within a football helmet.

FIG. 28 is a side view of a family cell in accordance with the subjecttechnology employed in a fabric within a football helmet.

FIG. 29 is a pressure map of the foot of a standing human, showing areasof expected pressure.

FIG. 30 is an overhead view of a family cell having a variable patternof second material to align with the areas of expected pressure from thepressure map of FIG. 29.

FIG. 31 is a pressure map of the thighs and buttocks of a sitting human,showing areas of expected pressure.

FIG. 32 is an overhead view of a family cell having a variable patternof second material to align with the areas of expected pressure from thepressure map of FIG. 31.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

The advantages, and other features of the system disclosed herein, willbecome more readily apparent to those having ordinary skill in the artfrom the following detailed description of certain preferred embodimentstaken in conjunction with the drawings which set forth representativeembodiments of the present technology and wherein like referencenumerals identify similar structural elements. It is understood thatreferences to the figures such as up, down, upward, downward, left, andright are with respect to the figures and not meant in a limiting sense.

Referring to FIGS. 1-4, a family cell on a shoe sole 150 is showngenerally at 100. The family cell 100 is formed by a series ofhomogenous inner bladders 102 a-c, formed from a common first material103 having a first elasticity. The inner bladders 102 a-c have exteriorsurfaces 104 a-c that are exposed to an outside environment (around thesole 150, not shown distinctly) and interior surfaces defining innerchambers 106 a-c for storing fluid 108 (i.e. liquid or gas) which arefluidly connected by a series of conduits 110 a-c. The conduits 110 a-cmay also include one or more valves 112 a-c (FIGS. 3-4) to control fluidflow in a particular direction. An intake conduit 114 fluidly connects apressure pump 116 to the inner chambers 106 a-c, and thus, the familycell 100. The pressure pump 116 is operable to provide fluid pressureinto the family cell 100 via the intake conduit 114. Arrow “a”represents the flow of fluid into the family cell 100 while arrows “b”and “c” show fluid flow throughout the family cell 100 via the fluidconnection conduits 110 a, 110 b. A pressure release valve 118 can befluidly connected to the inner chambers 106 a-c (i.e. FIG. 1) to relieveany excess pressure. Arrow “d” shows the flow of fluid 108 out of thefamily cell 100 when the pressure has exceeded a set threshold.

The inner bladders 102 a-c of the family cell 100, being formed from asimilar first material 103, have similar elastomeric capability. Forexample, referring to FIG. 2, the inner bladders 102 a-c are fluidlyconnected and share a common inner pressure. Since the inner bladders102 a-c have similar elastomeric capability and share a common innerpressure, they are stretched, by the inner pressure, to a similar length“e”.

Referring now to FIGS. 5-6, a family cell 200 is shown embedded in acushion for a shoe sole 250 in accordance with the subject technology.While the shoe sole 250 is shown for explanatory and illustrativepurposes, it should be understood that the subject disclosure isoperable within a wide range of technology, for example, in cushioningtechnology such as seat cushion, pillows, and helmets. The shoe sole 250shown is different than the shoe sole 150 of FIGS. 1-4 in that itincludes a second material 220 across two hybrid bladders 202 b, 202 c.

The second material 220 has a second elasticity that is less than thatof the first material 203. Therefore, in the embodiment shown, differentamounts of second material 220 are applied to the inner bladders 202 b,202 c to form hybrid bladders 222 b, 222 c of varying elasticity, atparticular locations of the shoe sole. For example, a large amount ofsecond material 220 is provided on the middle bladder 202 b under thearch portion of the sole 250 to form a hybrid bladder 222 b with agreatly reduced elasticity. An intermediate amount of second material220 is provided to the rightmost inner bladder 202 c, under themetatarsal portion of the shoe, to form a hybrid bladder 222 c with asomewhat reduced elasticity. Meanwhile the leftmost inner bladder 202 a,located below the calcaneus portion of the sole 250, does not have anysecond material 220 attached to it. The hybrid bladders 222 b, 222 chave reduced elastic qualities as a result of the second material 220affixed to the exterior surfaces 204 b, 204 c. For example, all threebladders 202 a-c are currently fluidly connected and subjected to acommon inner pressure. Although the bladders 202 a-c are made from thesame first material 203, the hybrid bladder 222 b with the most secondmaterial 220 attached experiences the least amount of elongation “b”. Bycontrast, the inner bladder 202 a with no secondary material 220experiences the greatest length of stretching “a” while the hybridbladder 222 c with an intermediate amount of second material 220 isstretched to a length “c” in between that of the other bladders 202 a,222 b. This is due to the second material 220 reducing the elasticity ofthe hybrid bladders 222 b, 222 c in accordance with the amount of secondmaterial 220 attached thereto. In this way, the shoe sole 250 can becustom formed to provide ergonomic benefits.

Referring now to FIG. 7, the subject technology is shown in use with afamily cell 300 containing only a single bladder 302. A first area 324of roughly half of the bladder 302 is covered by a second material 320,forming a hybrid bladder 322, while a second area 326 of the other halfof the bladder 302 remains formed from only the first material 303. Inthis case, the second material 320 is extremely resistant to stretch.Therefore, when the family cell 300 is subjected to an inner pressure,the first area 324 stretches negligibly, or not at all, while the secondarea 326 experiences visible stretching “a”. In the embodiment shown,the narrower outer surface 328 represents the outer surface when thefamily cell 300 has been subjected to little or no outside pressure.Once the family cell 300 has been subjected to an inner pressure, theportion of the family cell 300 not covered by the second material 320expands, stretching by a length “a”, to have a wider outer surface 330.The stretching length “a” lessens near the arch portion 325 of the sole350, where some area is covered by second material 320 and some is not.The stretching length “a” is non-existent near the middle of first area324 which is completely covered by the second material 320.

Referring now to FIGS. 8-9, the shoe sole 350 of FIG. 7 is shown, exceptthat the family cell 400 does not include a secondary material. In FIG.8, the family cell 400 is shown with little or no inner pressure, whileFIG. 9 shows a comparison of the outer surface of the family cell whenit has an inner pressure 430 versus when it does not have an innerpressure 428. Thus, as seen in FIG. 9, the inner pressure causesexpansion of the sole to a length “a” around the entire sole, and theexpansion is not controlled through use of a second material, as seen inFIG. 7. Thus providing a second material, as in FIG. 7, can providebenefits, such as ergonomic benefits, by changing the elasticity of thefamily cell 400, and thus controlling expansion, in select locations.

Similarly, referring to FIGS. 10-13, family cells 500, 600 with twobladders 502 a, 502 b and 602 a, 602 b respectively, are shown. As inFIGS. 7-9, the expansion “a” of the family cell 600 with no secondmaterial (FIGS. 12-13), can be compared to the expansion “b” of the samefamily cell 500 having second material 520 over one of the innerbladders 502 a (FIGS. 10-11). As discussed before, the second material520 limits the expansion of the inner bladder 502 a to a length “b” thatis less than the length “a” of expansion of the bladders 502 b, 602 a,602 b with no second material 520.

As seen above, it should be understood the subject technology can beemployed with a range of bladder quantities. While smaller quantities ofinner bladders are typically shown for explanatory purposes, the subjecttechnology can be employed with any number of inner bladders, as neededto facilitate the purpose of the various products with which the subjecttechnology is used.

The second material may be formed by using various techniques such asmolding, laminating, casting, or silk screening. One skilled in the artwill understand that the ideal technique will depend on type of productwith which the user is incorporating the subject technology. For examplesilk screening could be used when a product application needs a thinmembrane, such as when the end product is a sleeping pillow. Highstrength needs, such as athletic and safety equipment, may requirelaminating of dissimilar materials, or foam with variable die cutpatterning to create both the desired elongation and cooling. Castingmay be used in an application that would require spacing for air coolingor channels for other functions. Casting can be used as a secondaryprocess in lower volume or higher cost applications and products.Molding may be preferred for higher strength materials that are suitablefor higher volume production. Molding may be used to achieve multiplefunctions, such as wiring, inclusion of other components, or mounting,for example.

Further, the second material can be formed using a variety of materialtypes, such as copper, diamond paste, polymer urethane, silicone, orother materials such as those typically employed in cushion technology.Alternatively, or additionally, the second material can be formed by oneor more fabrics of the type typically employed in cushion technology.The second material type, as well as the forming technique, can bechanged depending on the desired properties and application. Forexample, by utilizing a second material that includes copper or diamondpaste, the second material can shield the family cell fromelectromagnetic and radio waves. By way of further example, silicone hasheat dissipation properties, so utilizing a silicone based secondmaterial can provide heat dissipation properties to the hybrid bladderto which it is attached, and therefore, to the family cell. This willallow the subject technology to also be used as a heat sink carryingheat away from the source. The second material can also be formed toincrease air circulation across the hybrid bladder. For example, diamondcompounds such as micro diamond infused aircool memory foam are added tomemory foams for cooling on pillows and beds. Diamond compounds may beused with silicone or urethane based materials in the casting, molding,laminating, or silkscreen process. Similarly, copper is used as earthground and may be incorporated into the material to allow a neutralizingfield for electromagnetic radiation.

The second material can also have a particular hardness depending on theproperties the user wishes to achieve. For example when the secondmaterial has a hardness of 65 to 85 Shore A, the second material issuitable for use in a shoe sole.

The second material may also be formed to show graphics on a surface ofthe fabric. Graphics may include lines and typeface for branding.Graphic lines of printed second material can be varied both in densityand line thickness to help achieve the correct elongation and to keepthe first material flexible. This can also help to control vibration ofany valves or conduits that pass fluid between the inner bladders.Another use of this manufacturing method can also achieve graphics bythe accurate placement of material and branding for the marketing of theproduct.

For example, referring to FIG. 10, lines of second material can bedesigned and applied such that they are oriented perpendicular to thenatural stretch of the material for the best results. If this method isbeing used for two way stretch material, a cross hatch pattern can beused. Thus, by running the lines of second material 520 in crosshatching pattern, running across the exterior surface of the hybridbladder along a longitudinal and transverse axis “c”, “d”, the secondmaterial 520 reduces elongation most effectively along those axes “c”,“d”. Other variable patterns can also be used, and are discussed morefully below.

Referring now to FIGS. 14-32, a variety of implementations of thesubject technology are shown. For illustrative and explanatory purposes,the technology is sometimes shown on a shoe sole (FIGS. 14-22, 30), apillow (FIGS. 23-24), a seat cushion (FIG. 31), or a football helmet(FIGS. 27-28) while at other times the technology is shown on a fabricor material, separated from any particular product (FIGS. 25-26).Therefore, as discussed above, it should be understood that thetechnology disclosed herein is suited for a wide range of particularproducts and applications outside of just shoe soles.

Referring now to FIG. 14, a shoe sole 750 in accordance with the subjecttechnology is shown. The shoe sole has a first material 703 which ispartially covered by a second material 720 of a lesser elasticity. Thesecond material 720 is provided such that from an overhead view gaps inthe second material 720 cause the first material 703 to show through inthe shape of irregular hexagons. More second material 720 is provided toareas of the sole 750 where a lower elasticity is desired. For example,as shown, the calcaneus portion 740 of the sole has a greater amount ofsecond material 720 while the metatarsal portion 742 has a lesser amountof second material 720.

Referring now to FIG. 15-18, the shoe sole 750 of FIG. 14 is shown. Forcomparison, the shoe sole 750 has a family cell 700 shown with anegligible inner pressure (FIGS. 15, 17) compared to a sole 750 wherethe family cell 700 has a noticeable inner pressure (FIGS. 16, 18). Whengiven an inner pressure (i.e. FIGS. 16, 18), the family cell 700, andtherefore the sole 750, expands, the expansion at each location of thesole 750 being proportional to the amount of second material 720 nearby.As such, the pressurized family cell 700 expands the greatest amount “a”(See FIGS. 16, 18) in the areas with the least amount of second material720.

Referring now to FIGS. 19-22, shoe soles 850, 950, 1050, 1150 withsecond material 820, 920, 1020, 1120 in a variety of patterns are shown.The variable patterns are applied on the hybrid bladders of a familycell (not shown distinctly on these figures) which, depending on whichpattern is employed, provide additional or different properties such asvarying elasticity across the family cell. The variable patterns can beemployed to different effects, such as to prevent stretching in variouslocations and also to reduce, or dampen vibrations across selectlocations of the family cell. For example, variable patterns could beemployed using a soft material over an area of expected pressure orimpact to reduce the velocity of any sudden force that strikes thatarea.

Referring now to FIGS. 23-24, a family cell 1200 in use with a fabric1201 in accordance with the subject technology is shown. In this case,the fabric 1201 has been shaped to form a pillow. The fabric 1201employing the subject technology functions much the same way as thetechnology as applied in the examples of the subject technology withrespect to shoe soles, as described above. For example, the fabric 1201includes a first fabric material 1203 that is covered, to varyingdegrees in different areas, with a second fabric material 1220 having alesser elasticity. When the fabrics are given an inner pressure, thevarious areas of the fabrics expand to various degrees depending on theamount of second fabric 1220 in that area. As seen in FIG. 24 thegreatest expansion “a” occurs in the areas with the least second fabric1220, while the areas with a large amount of second fabric 1220 havelittle or no expansion.

By providing the subject technology with a fabric 1201, the subjecttechnology can incorporated in a wide range of products. Much like thevarious patterns shown above with respect to the shoe sole examples(i.e. FIGS. 19-22), the pillow could use fabric having a variety ofpatterns, as seen in FIGS. 25-26. The fabric of the subject technologyalso has a variety of applications, such as in a football helmet, tohelp avoid concussions and other head injuries, as seen in FIGS. 27-28.

Referring now to FIGS. 29-32, the subject technology is shown in variousembodiments corresponding to pressure maps. For example, in FIG. 29, thepressure map of the foot of a standing human is shown generally at 1570.Accordingly, in FIG. 30, the subject technology is employed with a shoesole 1550 to provide ergonomic benefits based on the area of greatestexpected pressure. Where the pressure maps shows a large amount ofpressure, little or no secondary material 1520 can be provided to allowthe greatest stretching of the shoe sole 1550 (i.e. the metatarsalportion 1542). These areas will then stretch the most, providing alarger cushion for a user's foot in areas that correspond with thegreatest expected pressure. By contrast, areas with lower expectedpressure (i.e. the arm portion 1543) have more second material 1520, andareas with an intermediate expected pressure have an intermediate amountof second material 1520.

Similarly, referring now to FIGS. 31-32, the subject is showncorresponding to the pressure map of a seat cushion 1680. As with thesole 1550 of FIG. 30, the areas with the greatest expected pressure arecovered with the least amount of secondary material 1620 (i.e. directlyunder the user's legs and buttocks) and vice versa. This can provideergonomic benefits to a user.

While the family cells and fluidly connected inner bladders shown hereinoften share a common inner pressure, it should be noted that innerbladders within a family cell need not have the same inner pressure.Valves between the inner bladders can allow certain of the innerbladders to have a lesser or greater pressure than other bladders, inaccordance with other products using “cell flow technology.”

It will be appreciated by those of ordinary skill in the pertinent artthat the functions of several elements may, in alternative embodiments,be carried out by fewer elements, or a single element. Similarly, insome embodiments, any functional element may perform fewer, ordifferent, operations than those described with respect to theillustrated embodiment. Also, functional elements (e.g., modules,databases, interfaces, computers, servers and the like) shown asdistinct for purposes of illustration may be incorporated within otherfunctional elements in a particular implementation.

While the subject technology has been described with respect topreferred embodiments, those skilled in the art will readily appreciatethat various changes and/or modifications can be made to the subjecttechnology without departing from the spirit or scope of the invention.

1-14. (canceled)
 15. A cushion comprising: an inner bladder having afirst material of a first elasticity; and a second material having asecond elasticity, the second material connected to an exterior surfaceof the inner bladder and forming a pattern thereon wherein the secondmaterial reduces the elasticity the inner bladder.
 16. The cushion ofclaim 15, wherein the cushion is the innersole of a shoe.
 17. A methodof controlling elongation of connected fabrics comprising: connecting atleast two first fabrics, the first fabric formed by a first materialhaving a first elasticity; and attaching a second fabric, the secondfabric formed by a second material having a second elasticity to thefirst fabric, wherein the second elasticity is substantially less thanthe first elasticity.
 18. The process of claim 17, wherein the secondmaterial forms at least one variable pattern.
 19. The process of claim17 wherein the at least one variable pattern corresponds with a pressuremapping diagram, the pressure mapping diagram reflecting areas ofexpected pressure between a cushion and a user.